BIC Volvo V70R Front Mount Intercooler System User Manual

Page 7

Volvo V70R Intercooler System

/ Installation Manual

Removing Factory Intercoolers and Tubes

Note: For this step of the installation process it will be necessary to
drain the engine coolant. At this point you may wish to replace your
engine coolant, as well as radiator hoses. We recommend replacing
hoses if they have been in use for more than two years or 20,000
miles, as they can become less ﬂexible and prone to cracking and
failure when handled.

The S60R utilizes two intercoolers, a large primary intercooler and a
small secondary intercooler, in the factory intercooler system. The pri-
mary intercooler is secured between the AC condenser and radiator
to form an assembly which is then attached to the radiator bulkhead.
To remove the primary intercooler you must detach the AC con-
denser and primary intercooler from the radiator. The radiator and AC
condenser will be lowered to extract the primary intercooler. The AC
system does NOT need to be evacuated form this process, though
care must be exercised when working with the various AC lines and
components to prevent damage.

4.1 Remove Secondary Intercooler
• Locate the secondary intercooler connection hoses on each end of

the secondary intercooler. Loosen all hose clamps (x4) for the left
and right connection hoses.

• Locate and remove the two mounting bolts securing the secondary

intercooler to the AC condenser (see Items A in Fig. 4.1).

• Remove secondary intercooler and intercooler connection hoses.

4.2 Remove Intercooler Inlet Hose and Outlet Tube
• Locate intercooler inlet hose (see Fig. 4.1).

• Loosen hose clamp securing intercooler inlet hose to intercooler.

• Loosen hose clamp securing intercooler inlet hose to the over-engine-pipe (OEP, the large tube running over top of engine

from front to rear). Remove intercooler inlet hose.

• Locate vacuum/boost port on intercooler outlet tube (see Fig. 4.1). Remove hose from port.

• Locate and loosen hose clamp securing intercooler outlet tube to intercooler.

• Locate hose clamp securing intercooler outlet tube to underside of engine intake manifold. Loosen hose clamp and remove tube.

4.3 Remove IAT Sensor Harness
• Locate the intake air temperature (IAT) sensor, located on intercooler out-

let (see Fig. 4.1). Disconnect wiring harness from IAT sensor. Locate and
remove bolt securing IAT sensor to intercooler (T15 Torx bit). Carefully
remove IAT sensor being sure not to damage O-ring seal.

4.4 Drain Engine Coolant
Note: You may wish to replace your engine coolant and radiator hoses as
part of routine maintenance.

• Locate the plastic radiator drain plug/nozzle at the lower right (driver side)

corner of the radiator (see Fig. 4.2).

• Remove cap from coolant reservoir in engine compartment.

• Position drain pan and loosen, but do not remove drain plug. Coolant will

drain without the drain plug being completely removed.

• When coolant completely drained, retighten coolant drain plug.

4.0

Figure 4.1

Illustration / Volvo Cars North America

Factory Intercoolers and Tubes

Secondary

Intercooler

Primary

Intercooler

Inlet

Tube

Outlet

Tube

IAT

Sensor

Vacuum/

Boost

Port

Figure 4.2

Coolant

Drain Plug